Cornelius Brewed Iced Tea, Lipton Brewed Iced Tea Double Valve Dispenser Installation & Service Manual
Lipton Brewed Iced Tea
Double Valve Dispenser
Training, Installation, & Service Manual
Part No. 630460171 May 7, 2002
©2001-2002, IMI Cornelius, Inc. Revision B
Safety & Specifications
Installation
Service
Training
Lipton Brewed Iced Tea Training, Installation, & Service Manual
630460171 ii May 7, 2002
Lipton Brewed Iced Tea Training, Installation, & Service Manual
Lipton Iced Tea Brewer
Training, Installation, & Service Manual
The products, technical information, and instructions contained in this manual are subject
to change without notice. These instructions are neither intended to cover all details or
variations of the equipment, nor to provide for every possible contingency in the installation, operation, or maintenance of this equipment. This manual supposes that the person(s)
working on the equipment are trained and skilled in working with electrical, plumbing,
pneumatic, and mechanical equipment. In addition to the information this manual provides, Cornelius expects proper installation that includes taking appropriate safety precautions as well as adhering and meeting all local safety and construction requirements.
To inquire about current revisions of this and other documentation, or for assistance please contact:
NGB.
505 Cleveland Street
Blairsville, GA.
30512
U.S.A.
Trademarks and copyrights:
Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, and Vista are registered
trademarks of IMI Cornelius.
Optifill trademark is pending.
LITB Dispenser US and Foreign Patents pending
Fresh Brewed Service:
------------ 1-866-LiptonT
------------1-866-547-8668
Email:
liptontea@ngbservice.com
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2001-02, All Rights Reserved, IMI Cornelius Inc.
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TABLE OF CONTENTS
SAFETY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
Read and follow all safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Recognize safety alerts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
Different types of alerts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
Safety Tips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Authorized Service Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Hot Water Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
CO2 (Carbon Dioxide) Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
Shipping And Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4
Key Things To Know - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4
Cleaning and Sanitation Practices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
SYSTEM OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
Function Keys - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
Language key - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
Menu key - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
Stop key - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
Rinse key - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
Run key - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
Menus and Modes of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
DATA VIEW mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
SET TIME mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9
SETTING THE TIME AND DATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Setting the RINSE TIME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9
ADJUST STRENGTH mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
SERVICE mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9
Display Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Tea Pump state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Sweetener valve state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Hot Brew water valve state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Rinse Water Valve State - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Cold water valve state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Tea Bag Sold out state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Sweetener Sold out state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Hot water temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Heater relay state - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Motor Volts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
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Normal Pour - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
SET-UP mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Tank Status - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
System Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Set-Up Tea Syrup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Set-Up Sweetener - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Set-up Cold Water - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Set-Up Hot Brew Water - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Timed Pour - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Control Board Inputs: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Control Board Outputs: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Capacities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Installation Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Electrical Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Environmental Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Initial Installation Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Delivery Inspection and Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Installation Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
LBIT Installation and set up sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Filling the Water Tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
Set-up Tea Extract - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
Set-up Sweetener - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
Set-up Cold Water - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
Set-up Hot Brew Water - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
Set-up the Clock and Rinse Times - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
Initial Rinse Cycle/Final Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - 23
Rinse Cycle Procedure (General) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
Sweetener BIB Installation (General) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Scheduled Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Daily Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Daily System Flush (Hot Water Rinse) Procedure - - - - - - - - - - - - - - - - - - - - 32
Rinse Cycle Program - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
Monthly Sanitizing Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
Preventative Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
Annual Pump Tubing Replacement Procedure - - - - - - - - - - - - - - - - - - - - - - 36
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Replacing Pump Tubing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
Service Advisory - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
WARRANTY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
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SAFETY
SAFETY INSTRUCTIONS
Read and follow all safety instructions
Read and follow all safety instructions in this manual and on the machine (decals,
labels, and laminated cards).
Before operating the machine, read and understand all applicable OSHA (Occupation
Safety and Health Administration) safety regulations available from the safety coordinator or supervisor.
Recognize safety alerts
This is the safety alert symbol used in this manual or on the machine. The
safety alert symbol is used to alert personnel to the potential of personal
injury, or damage to the machine.
Different types of alerts
There are three types of safety alerts:
DANGER: Indicates an immediate hazardous situation
which if not avoided WILL result in serious injury,
death, or equipment damage.
WARNING: Indicates a potentially hazardous situation
which, if not avoided, COULD result in serious injury,
death, or equipment damage.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate
injury or equipment damage.
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SAFETY TIPS
• Carefully read all safety messages in this manual and safety signs on the
machine.
• Keep safety signs in good condition and replace missing or damaged safety signs.
• Learn how to operate the machine and how to use the controls properly.
• Do not let anyone operate the machine without proper training.
• Keep the machine in proper working condition.
• Do not allow unauthorized modifications to the machine.
• The brewer can dispense hot water. During the rinse operation water temperature
can exceed 205°F. Certain flow tubes in the brewer carry hot water. Use Caution.
• The heater tank contains no replaceable parts. The entire heater tank must be
replaced if service is required.
• Be certain that the dispenser nozzle is snugly threaded onto the spigot assembly.
AUTHORIZED SERVICE PERSONNEL
CAUTION: Only trained and certified electrical,
plumbing, and refrigeration technicians should
service this unit. ALL WIRING AND PLUMBING MUST
CONFORM TO NATIONAL AND LOCAL CODES.
HOT WATER WARNING
WARNING: This unit dispenses HOT water (160° F
(71°C) - 205° F (96°C) during the rinse cycle.
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CO2 (CARBON DIOXIDE) WARNING
WARNING: CO2 Displaces Oxygen. Strict Attention
must be observed in the prev ent ion of CO2 gas leaks
in the entire CO2 and system. If a CO2 gas leak is
suspected, particularly in a small area, immediately
ventilate the contaminated area before attempting to
repair the leak. Personnel exposed to high
concentration of CO2 gas will experience tremors
which are followed rapidly by loss of consciousness
and death.
CAUTION: PRECAUTIONS TO BE TAKEN IN
STORAGE: Store and use with adequate ventilation.
Firmly secure cylinders upright to keep from falling or
being knocked over. Screw valve protection cap firmly
in place by hand. Store only where temperature will
not exceed 52°C (125°F). Store full and empty
cylinders separately. Use a first-in, first-out inventory
system to prevent storing full cylinders for long
periods.
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CAUTION: PRECAUTIONS TO BE TAKEN IN
HANDLING: Protect cylinders from damage. Use a
suitable hand truck to move cylinders; do not drag,
roll, slide, or drop cylinders. Never attempt to lift a
cylinder by its cap; the cap is intended solely to
protect the valve. Never in sert an objec t (e.g. wrench,
screwdriver, pry bar) into cap openings; doing so may
damage the valve and cause a leak. Use an adjustable
strap wrench to remove over-tight or rusted caps.
Open valve slowly. If valve is hard to open,
discontinue use and contact your supplier. Never
apply flame or localized heat directly to any part of the
cylinder. High temperatures may damage the cylinder
and could cause the pressure relief device to fail
prematurely and venting the cylinder contents. Never
strike an arc on a compressed gas cyl inder or make a
cylinder part of an electrical circuit. For additional
information on storage and handling, refer to
Compressed Gas Association (CGA) pamphlet P-1,
“Safe Handling of Compressed Gases in Contai ners,”
available from the CGA.
Shipping And Storage
CAUTION: Before shipping, storing, or relocating the
unit, product extract systems must be sanitized;
completion requires purging all sanitizing solution
from the systems. In addition, all liquids, after
sanitizing, must be purged from the unit. A freezing
ambient environment causes residual sanitizing
solution or water remaining inside the unit to freeze
resulting in damage to the internal components.
K
EY THINGS TO KNOW
• Always unplug/disconnect the power to the dispenser before servicing.
• Verify adequate water line pressures and volumes.
• Verify water quality, optimum dispense taste may require water treatment.
• Rinse water is very hot (160°- 205° F (71°- 82°C)).
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• Do not activate the heater until the water tank is full.
• Rinse must be performed at least once every 24 hours or the brewer will lock out
and will not dispense product.
• The heater tank contains no replaceable parts. The entire heater tank must be
replaced if service is required.
• Warning Battery Life: Disconnecting the power supply or turning the power
switch off for longer than 48 hours will result in a service call to reprogram the
dispenser. The battery will recharge itself when the power is restored to the
board.
CLEANING AND SANITATION PRACTICES
It is imperative that the daily cleaning procedures, hot water flush, and monthly sanitizing
procedures be followed as outlined in chapter 4.
WARNING: Failure to follow the scheduled cleaning
and sanitizing procedures shown in chapter 4 may
result in the growth of potentially harmful bacteria in
the dispensed tea product.
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Lipton Brewed Iced Tea Training, Installation, & Service Manual
SYSTEM OVERVIEW
The Lipton Iced Tea Brewer (LBIT) looks and operates like a leaf tea brewer. The LBIT
instantaneously mixes and dispenses tea extract, hot water, cold water, and liquid sweetener to provide a finished tea product. Unlike leaf tea brewers, the LBIT does not have
high maintenance and operational costs, and it is not as susceptible to the bacterial growth
inherent to leaf tea brewers.
The following descriptions provide basic information of:
• Theory of Operation
• Function Keys
• Menus and Modes of Operation
• Capacities.
THEORY OF OPERATION
The fresh brewed process involves the mixing of concentrated (100:1) tea extract with hot
water in order to brew the tea. A residence time of about 0.50 seconds ensures that the tea
mixture is adequately dispersed and increases clarity.
A metered quantity of cold water is added to the brewed tea mixture to produce finished
tea. The cold water reduces the temperature of the final product to approximately 90° F
(32° C). This temperature is similar to iced tea product dispensed from leaf tea brewers.
FUNCTION KEYS
The LBIT controller is a specific purpose circuit board residing within the brewer. The
controller monitors inputs, controls outputs, and provides service and display functions.
Keys providing the basic operations within the controller are labeled Language (-), Menu
(+), Stop (#), Rinse (<), and Run (>). The base operations of the keys are as follows.
Language key
Pressing this key will toggle the display between English and Spanish.
Menu key
Pressing this key will advance the display to the beginning of the next menu item.
There are five menu functions that may be selected: Data View, Set - Time, Strength,
Service, and Set-up.
Stop key
Pressing this key will put the brewer in stop mode. In this mode all normal functions
occur except that tea will not be dispensed when the spigot handle is pulled.
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Rinse key
WARNING: This unit dispenses HOT water (160° F. 205° F. (71°C - 96°C) during the rinse cycle.
Pressing this key will place the brewer in the rinse cycle mode. In this mode the
brewer will require user intervention to initiate each flush of hot water through the
system. This is done by opening the spigot when prompted to do so on the display.
After the rinse is completed, the brewer automatically returns to run mode.
Run key
Pressing this key will return the brewer to run mode. This is the only mode where a
normal dispense is available.
NOTE: While in run mode, if an alarm occurs (over temp, sold out,
etc.) the brewer will display the current er rors being de tected. Pressing the LANGUAGE key will step through the current errors being detected.
MENUS AND MODES OF OPERATION
Pressing the MENU key will scroll through five basic modes in a round robin fashion. The
menus and their order are: DATA VIEW, SET TIME, STRENGTH, SERVICE, and SETUP.
To enter a selected mode, the STOP (#) key may be pressed. Once a particular mode is
entered, the keypad keys are referenced as (-), (+), (#), (<), and (>). Display screen
prompts will tell the operator what to do. In general the keys will have the following function: Scroll forward or backward press (>) or (<), change a value press (+) or (-), to exit or
enter a mode or sub-mode (#).
DATA VIEW mode
Scroll to the Data View Mode using the menu key. Press the (#) key to enter. Press the
(>) to advance. The Data View sub modes include: Time of Day, Water Temperature,
Gallons of tea poured in the last 30 days, Total Gallons of tea poured over the life of
the brewer, Number of tea sold outs recorded (bags used), Number of sweetener sold
outs recorded (bags used), and the Number of days the brewer has been in operation.
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SET TIME mode
SETTING THE TIME AND DATE
1. Press MENU until ENTER SET TIME? is displayed.
2. Press (#) key to enter SET TIME and press (>) to advance.
3. Press the (#) key to en ter SET CLOCK?. Read the flash screens.
Press (>) or (<) key to move the cursor. Press (+ ) or (-) keys to
change settings. Press (#) key twice to save new settings.
Setting the RINSE TIME
Contact the manager or the “decision maker” of the restaurant. Request a
time of the day when the brewer will be cleaned. Recommend a time when
they open the restaurant in the morning. This time should be when they normally clean their dispensing equipment, or when there are no customers at
the restaurant, or a slow time of the day.
1. Press the (#) key to enter SET RINSE TIME?. Read the flash
screens. Press (>) or (<) key to move the cursor. Press (+) or (-)
keys to change settings. Press (#) key twice t o save new settings.
2. Press (#) twice to save the rinse time.
3. Press the (#) key to exit SET TIME.
ADJUST STRENGTH mode
1. Press MENU until ENTER STRENGTH? is displayed.
2. Press (#) to enter and (>) to advance.
3. Read the flash screens. Press (+) or (-) key to change strength settings.
Press (+) or (-) keys to change set tings. The allowed adjustment range in
this screen is +/-5% of the installed strength. Ea ch p ress o f th e (+) or (-)
keys will change the tea strength by 1% until the 5% maximum change is
reached.
4. Press (>) to advance and (#) to exit.
SERVICE mode
1. Press MENU until ENTER SERVICE? is displayed.
2. To enter Press and hold the STOP key and then press the RUN key.
3. Press (>) to advance to the following sub-modes.
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4. Press (#) to enter or exit the sub-modes and follow the display instructions.
DISPLAY ERRORS
Displays most recent error first Press (>) to advance through all errors.
TEA PUMP STATE
This screen displays the current state of the Tea pump (ON/OFF). Pull the
dispense lever to start the flow of tea. Release the dispense lever to stop the
flow of tea.
SWEETENER VALVE STATE
This screen displays the current state of the Sweetener valve drive (ON/OFF
or DISABLED). Pull the dispense lever to start the flow of sweetener.
Release the dispense lever to stop the flow of sweetener.
NOTE: If the brewe r is instal led as unsweete ned, the val ve is overridden and locked out, and the controller skips over this function in Service mode.
HOT BREW WATER VALVE STATE
This screen displays the current state of the Hot water valve drive (ON/
OFF). Pull the dispense lever to start the flow of hot water. Release the dispense lever to stop the flow of hot water.
Note: The Hot water valve drive operates both the input and output
Hot water valves at the same time.
RINSE WATER VALVE STATE
This screen displays the current state of the Rinse water valve drive (ON/
OFF). Pull the dispense lever to start the flow of hot water. Release the dispense lever to stop the flow of hot water.
COLD WATER VALVE STATE
This screen displays the current state of the Cold water valve drive (ON/
OFF). Pull the dispense lever to start the flow of cold water. Release the dispense lever to stop the flow of cold water.
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